Manhole, roadway and walkway repair

ABSTRACT

A method for repairing roadway and pathway defects utilizes a filling material and a primer. The method calls for applying the primer to an edge of the defect; pouring the filling material into the defect; and curing the filling material to form a patch that is even with the road.

FIELD OF THE INVENTION

The invention relates to improved methods for servicing, repairing or resurfacing roadway and walkway surfaces including manhole structures.

BACKGROUND

A manhole is an opening to an underground utility vault that provides an access point for performing maintenance on underground utilities. A typical manhole structure includes a metal frame or ring that is covered by a lid to prevent accidental or unauthorized access to the manhole.

Roadway surfaces, including the area surrounding manhole structures, may deteriorate, producing uneven surfaces which disrupt traffic and create liabilities for damage or injury. After a road is paved or resurfaced, the top of the manhole must be at the same level as the surrounding concrete or asphalt road surface. Typically, this is assured by breaking up the concrete or asphalt immediately surrounding the manhole ring and raising the top of the manhole cover and ring to the new road level. Next, liquid concrete is poured around the manhole ring to a form a collar (as shown in FIG. 1) that also must be at the street level so that traffic can pass safely and smoothly over the covered manhole and its collar.

The existing process is, however, expensive due to the special equipment, materials and labor required to remove the concrete or asphalt and to pour the concrete for the collar. In addition, the process is time-consuming as workers first place barriers, then jackhammer loose the old collar, manually raise and secure the manhole cover and ring, pour concrete and wait for the concrete to cure to a suitable hardness before opening the road to vehicle traffic. Furthermore, workers must remain on location at the manhole structure until the concrete cures to ensure that there is no tampering with the concrete. This entire process, i.e., the creation of the collar and the curing of the concrete, may take up to seven hours during which traffic continues to be rerouted. Moreover, since the concrete has no elasticity and is subject to breakage over time, there is the possibility that substantial maintenance costs could be required in the future.

The same challenges occur when cracks, potholes or patching develop as surfaces deteriorate. Repairing these defects is often difficult and/or prohibitively expensive because of the special equipment required to perform suitable repairs. Frequently, temporary inadequate measures are implemented and need to be redone frequently until proper repairs or resurfacing are afforded.

SUMMARY

According to one aspect of the invention, a method for filling a pot hole in a road utilizes a filling material, primer and catalyst. The method has the steps of applying the primer to an at least a portion of the pot hole; pouring the filling material into the pot hole; and curing the filling material to form a patch that is even with the road. The catalyst is applied to the entire surface of the filling material. The step of applying the primer is preceded by a step of cleaning the pot hole. The step of curing the filling material includes spraying the surface of the filling material with catalyst. When the pot hole is a defect near a manhole, the pot hole is cleaned, primed, filled with filling material and covered with catalyst.

In another embodiment, a method of applying a filling material in the space around a manhole structure prevents deterioration of a collar formed from concrete. This method has the steps of pouring the concrete into the space around the manhole structure to form the collar; applying the filling material over the collar; and curing the filling material to form a rigid support around the manhole structure which absorbs impacts produced when vehicles pass over the manhole structure. The filling material is applied to the entire surface of the wet concrete. The step of curing the filling material includes spraying the surface of the filling material with the catalyst. The step of curing the filling material includes spraying the surface of the filling material with catalyst and then water.

In yet another embodiment, there is provided a method for raising the level of a manhole structure and collar to the level of a resurfaced road utilizing a cover, a separator ring, and a filling material. This method has the steps of applying the cover on top of the manhole structure and the collar; erecting protection of the manhole cover and ring from being covered with the asphalt; pouring the asphalt over the road and cover; removing the protection from the manhole lid and ring; positioning the separator ring around the lid; applying the filling material over the manhole structure and the collar to form a secondary lid and surround each having a height equal to the resurfaced road; and removing the separator ring from around the lid. The primer is optionally applied to the manhole cover and ring before applying the filling material. The step of applying the filling material is optionally followed by a step of leveling the filling material. The step of removing the separator ring is followed or preceded by curing the filling material. The step of curing the filling material may include spraying the surface of the filling material with the catalyst.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a manhole lid surrounded by a collar performed utilizing a prior art process;

FIG. 2 is a sectional view of a manhole structure including a filling material applied over a concrete collar in a ring-surround area around a manhole structure according to one embodiment of the invention;

FIG. 3 is a sectional view of a manhole structure, including a ring and a lid, with a concrete collar disposed within a ring-surround area along a road ready to be resurfaced;

FIG. 4 is a sectional view of the manhole structure and concrete collar wherein an asphalt road surrounding the collar has been ground down;

FIG. 5 is a section view of the manhole structure wherein a cover has been applied over the manhole structure and the collar according to another embodiment of the invention;

FIG. 6 is a sectional view of the manhole structure wherein the cover, and the asphalt on the cover, have been removed;

FIG. 7 is a sectional view of the manhole structure including the filling material poured on top of the lid and the collar to a level even with a new asphalt layer;

FIG. 8 is a sectional view of the manhole structure including a separator ring applied around the lid;

FIG. 9 is a perspective view of the separator ring; and

FIG. 10 is a side view of the separator ring with male and female adjustment mechanisms disengaged.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present methods of repairing roads and walkways are often too expensive and time consuming Budgets are shrinking and major cities are reporting months-long delays in fixing paved surfaces. Presently, roads and walkways are congested, and rerouting traffic for time-consuming repairs also inconveniences drivers and pedestrians. Cheap repairs, such as a cold patch, may only last until the first car or truck wheel accelerates on the patch. Longer-lasting repairs are accomplished with hot materials, which require special equipment, longer detours and longer motorist delays.

We invented methods to overcome these problems with conventional repairs of paved surfaces. Our methods employ quick curing materials that truly stick to the pavement being repaired. Not only is time saved in the repair methods, but the repairs last longer. Whenever time is saved and the lifetime of the repair is increased, there are immediate and long-term savings for payers.

Our methods are performed with ordinary road maintenance equipment and vehicles. The use of expensive, specialized equipment is eliminated. There is less need for skilled tradesmen. An important factor is the filling material, whose components are available from a number of chemical manufacturers, including but not limited to BASF, Stockmeier, APF, Marchem, Key Resin and Degussa construction chemicals. The repair process utilizes common materials including but not limited to recycled rubber, synthetic rubber, recycled asphalt, asphalt pellets, aggregate of various sizes, other materials having similar properties, including any material that one of ordinary skill in the art would appreciate as interchangeable with those described above.

In one embodiment, the filling material utilizes recycled rubber pellets or granules of various sizes. The rubber and or other materials may be pre-coated with urethane, wetting agent and catalyst and mixed together with a primer and an optional colorant. Such a combination encapsulates rubber or other materials during the mixing process to form a preferred filling material. The filling material is sent to users as part of an installation package. The installation package includes the pre-coated rubber and pre-measured bags of the appropriate chemicals and agents. The filling material (made this way or not) may be combined off site or combined at any location.

To make the filling material, a user places a desired amount of a filler such as pre-coated rubber into a portable mixer, adds a predetermined (by weight) amount of the binder chemicals and agents, and mixed. The filling material can then be poured into place at a desired location. The amounts of filling material and chemical agents may be varied to control the final hardness of the filling material and to control the amount of time required for the filling material to harden. For example, one mixture may speed hardening and increase the hardness of the filler while another mixture combination may allow more time for repair placement and form a more compliant repair.

In another embodiment, the filling material is a liquid that is elastic, is fast-curing, and increases durability (to the pounding of the paved surface). The filling material in this embodiment is strong (with a tensile break elongation of about 75% and a peak stress of about 60 psi) yet also acts as a cushioning surface.

Primers include but are not limited to a variety of urethanes, epoxies, wetting agents and catalyst. Those skilled in the art can select other primers, based on the characteristics of the chemical compounds and compatibility with the ingredients used in the filler material

By varying the type and proportion of filler and primer, those skilled in the art can readily adapt the combination to produce the desired characteristics, such as density, compressibility, elongation, and cure time for the particular conditions and composition of the site to be repaired.

The filler and primer may be prepared in a large mixer in a construction yard. Containers can be filled with such filling material, loaded onto any available vehicle and taken to preplanned routes for repair of numerous sites, such is called proactive. On the other hand, a reactive kit of a small container of filling material and packages of the other chemicals can be supplied to city workers to immediately fill a pothole they encounter.

The basic method of repair optionally begins with cleaning the surface of the “pothole” which can be defined as any crack, hole, opening, or flaw in a roadway, pathway or expansion joint). The pothole edge and surroundings are also preferably cleaned. Often there is some loose asphalt or concrete that can be removed with a simple sweeping or vacuuming Next, the cleaned site is prepared by contacting its surface(s) with primer and catalyst. Spraying the primer and catalyst is preferred as it tends to cover the surface area more completely, although other application methods can be used. The filler and primer are combined on site (if that is the choice) to produce filling material, or premixed filling material is provided. Filling material is applied to partially or entirely fill the pothole and optionally leveled with a trowel or other handy device. Another application of catalyst is sprayed onto the filling material. If no additional layer of filling material needs to be applied, the surface primer is sprayed with water. The water spray quickly “sets” the primer and allows motor vehicles on the surface in less than an hour, preferably less than 40 minutes and most preferably less than 30 minutes. Alternately, if the binder mix is already added to the filling material, the primer need only be used to line the pothole and the leveled surface. For this method, the road may be reopened within about two hours of arrival at the scene.

In general, the pothole repaired by the inventive method lasts as long as the road lasts due to the fact that the filling material is resilient and adheres to the subsurface and surrounding surface. Prior techniques for filling pot holes allow water dislodge the repaired surface such that when a vehicle passes over the filled pot hole, the repair to the pot hole is compromised due to the resulting water pooling and floating the patch. In the method according to the embodiment, the filling material may be made to be non-porous, as is the seal between the old surface and the filling material. Thus, no water passes through the filling material. In addition, the integrity and longevity of the repair is greater than any current system since the filling material expands and contracts with temperature changes.

Adapting the methods we invented for handling potholes, we have invented unique methods for rapid, efficient preparation of manhole and similar structures in a trafficked surface. Prior methods have utilized a process whereby when a road is resurfaced, the manhole cover structures are freed with a jackhammer, manually raised to the level of the new surface, and concreted in place again. These steps require two types of tradesmen, specialized singal purpose equipment and may take days to complete. Prior methods have utilized concrete collars around these structures. This creates major problems in that the concrete often gives out before the surrounding road. Basically, when a road is resurfaced so that the level is higher, we provide time, material cost and personnel savings with the manhole management. Skipping the steps and the concrete collar of the above paragraph, we protect the manhole cover and its ring during resurfacing and then clean them. Next we place a thin separator between the manhole cover and its ring. Then we apply primer to the manhole cover and surrounding resurfacing material. We then apply the filling material to the manhole cover and ring until the filling material is even with the level of the road resurfacing. It does not matter if the manhole cover and ring are askew, and variable amounts of filling material are applied to different sides. Then we apply a catalyst to the manhole cover and ring. After a short delay, we remove the lid ring separator, which leaves a space between the manhole cover and ring, permitting the usual easy removal of the manhole cover as needed.

Alternately, if the concrete around the manhole is damaged, it need not be replaced. With our invention, the damaged surface is cleaned, primed and filled in with filling material, and coated with catalyst and water. This simplified process saves considerable time, materials and personnel cost. Sometimes it is considered advisable to replace the concrete surround. In this case, new concrete may be poured in a collar shape but only to several inches under the surrounding roadway. Then we trowel our filling material onto the wet concrete. Because our material dries much faster and provides a stable surface within about two hours, we decrease the usual wait for concrete curing and provide a resilient surface that lasts longer and increases the longevity of the underlying concrete collar.

Referring now to FIG. 1, a conventional configuration for an area surrounding a manhole structure is shown and includes a concrete collar formed around a manhole ring and lid. The concrete collar is formed when a road is paved or resurfaced with asphalt to provide rigidity in the area surrounding the manhole structure. Concrete however deteriorates over time.

Referring to FIG. 2, a method according to one embodiment of the invention is provided to address the deterioration problem with concrete collars. FIG. 2 shows a manhole structure, generally shown at 10, having a ring or frame 12 that defines an opening 14. A lid 16 engages the ring 12 to cover the opening 14. The lid 16 is removable to allow access to an area below the manhole structure 10 via the opening 14. The manhole structure 10 is disposed along a road 18 that may be paved using asphalt or concrete. It is desired that the road 18 and the ring 12 of the manhole structure 10 be at the same level to ensure that traffic can pass safely and smoothly over the manhole structure 10.

The method according to one embodiment includes the step of removing the asphalt in a ring surround area 20 after the road 18 has been paved or resurfaced. The ring surround area 20 may be generally circular but it is appreciated that the particular shape and size of the ring surround area 20 may vary. Concrete is then poured into the ring surround area 20 to form a collar 22. The particular height of the collar 22 may vary. However, the collar 22 will not be at the same level as the paved or resurfaced road 18. When the concrete is still wet, a filling material 24 is poured on top of the collar 22. The filling material 24 is troweled to its desired form. Finally, the filling material 24 is allowed to cure using a spray mist of catalyst and/or water.

When the manhole structure 10 is being repaired in an existing road (where the road is not being resurfaced), the use of the filling material 24 reduces the amount of time that traffic needs to be diverted around the repair by five or more hours. This greatly reduces labor, equipment, and materials costs.

The resulting joint where the manhole ring 12 or the collar 22 meets the road 18 is smoother. Also, both the manhole structure 10 and vehicles passing over the manhole structure 10 will not take as large punishment due to the shock absorbing qualities of the filling material 24. Further, the processes set forth in the described embodiments will reduce maintenance costs when compared to typical existing processes.

It is also appreciated that in an alternative embodiment, the filling material 24 may be poured around the ring surround area 20 in the absence of a concrete collar 22.

Referring to FIGS. 3 through 10, a method according to another embodiment is provided for raising a height of the manhole structure 10 and the collar 22 to the level of the road 18 that has been resurfaced. As mentioned above, the manhole structure 10, including its ring 12 and lid 16, is surrounded by the collar 22. Initially, the manhole structure 10, the road 18, and the collar 22 are at the same height. The resurfacing process begins by grinding down the asphalt, as shown in FIG. 4, to prepare the road 18 for a new asphalt layer 27. Before the new asphalt layer 27 is laid down, a cover 26 is positioned over the manhole structure 10 and the collar 22 to protect the lid 16 and the collar 22 from direct contact with the new asphalt layer 27. The cover 26 in one embodiment is formed from metal but it is appreciated that the cover 26 may be formed from any of numerous materials. The new asphalt layer 27 is then laid down over the road 18 and the cover 26, as shown in FIG. 5. After the resurfacing of the road 18 is complete, the cover 26 and the new asphalt poured on the cover 26 are removed from the manhole structure 10. At this point, the manhole structure 10 is at the same level as it was before the resurfacing process started, and the road 18 is at a new level that is higher than the manhole structure 10 (as shown in FIG. 6).

Referring to FIGS. 7 through 10, a separator ring 28 is applied around the lid 16 of the manhole structure 10. The separator ring 28 includes an elongated main body 30 having opposing ends 32, 34. Male 36 and female 38 adjusters are located at the respective opposing ends 32, 34 to allow the separator ring 28 to fit around lids 16 of varying sizes. The separator ring 28 also may include at least one handle or ring lifter 40 extending upwards from the main body 30 to allow removal of the separator ring 28, as described in further detail below. A lifting hole plug 42 is applied to any lifting holes in the lid 16 of the manhole structure 10 at the same time that the separator ring 28 is positioned around the lid 16. The lifting hole plug 42 may be coupled to the separator ring 28 or separate therefrom.

Once the separator ring 28 is in place around the lid 16 of the manhole structure 10, the filling material 24 is poured over the manhole structure 10, including the ring 12 and the lid 16, and the collar 22 to form a secondary lid 44 surrounded by a surround 46 (as shown in FIG. 7). Because the separator ring 28 is in place while the filling material 24 is being poured, the space occupied by the separator ring 28 will be free of the filling material 24. The secondary lid 44 and the surround 46 each have a height that is equal to the height of the resurfaced road 18. This eliminates the need for adjusting the height of the ring 12 of the manhole structure 10. When the filling material 24 starts to cure, the separator ring 28 is lifted out of place using the handle 40 and the lifting hole plugs 42 are removed. The secondary lid 44 is able to be lifted off when desired in the same fashion as the lid 16 of the manhole structure 10. The edges of the secondary lid 44 are smoothened out with an appropriate tool and the filling material 24 is allowed to cure. The road 18 may be ready to be opened in as little as 20 minutes. As a result, there is a substantial reduction in the time and labor required to resurface the road 18.

When the road 18 is being resurfaced, the embodiments described herein result in a significant reduction of costs. There is no longer the need to locate, uncover, remove, and replace prior collars or to adjust manhole ring heights, which results in significant savings in time and labor since a single trade contractor can complete the project. By covering the manhole lid 16, the manhole ring 12, and the collar 22 during resurfacing and then pouring the filling material onto the uncovered manhole lid 16, the manhole ring 12, and the collar 22, the manhole structure 10 and the collar 22 can be raised, leveled, and strengthened in a single process. In addition, the possibility of breakage and associated repair expenses are reduced. Further, this same process can be repeated whenever the road 18 is resurfaced in the future.

The filling material 24 greatly reduces the possibility of damage caused by the deterioration of the collar 22. The filling material 24 on the lid 16 has a cushioning effect which protects the ring 12 from harsh shocks which are typically a major cause of ring failure.

In an alternative embodiment, silicone filler is applied to the space between the lid 16 and the ring 12. The separator ring 28 will then sit on top of the space between the lid 16 and the ring 12. The separator ring 28 is lifted out of place once the filling material 24 has been applied on top of the manhole structure 10 and the collar 22. And eventually the silicone dissolves so that the space between the lid 16 and the ring 12 is maintained.

In a method according to yet another embodiment of the invention, the filling material 24 may be utilized to fill pot holes that occur in asphalt or concrete roads. It is appreciated that the term “pot holes” is to be defined broadly and shall include any crack, hole, opening, or flaw in a road surface or expansion joint. The initial step in the method is to remove any debris out of the pot hole. Next, the surrounding asphalt or concrete edge and the bottom of the pot hole are coated with the primer. The filling material 24 is then mixed together and placed into the pot hole. The filling material 24 in the pot hole is troweled to a smooth level surface to form a patch that is even with the road 18. After this permanent repair, the road 18 may be reopened within twenty minutes.

For this example, see the pictures of a deteriorated collar with a sunken lid and the typical process of breaking away the old concrete, manually raising the frame-ring structure, pouring new concrete then adding the filling material to reduce the curing time, etc. The filling material has the long-term advantage of “shock absorption” relative to the foreshortened longevity of the stiff, inflexible “crown, frame and ring of the manhole structure.” Another benefit is improved “driver comfort” upon passage over the repair.

Another important aspect of the invention is that it is simple and easy to perform on any size or shape of opening and in any surrounding surface including asphalt, concrete or even brick as in junction box repair. Moreover, the labor saving and the permanency of the “process” make the system extremely valuable and unique. There simply has been no cost effective way to level junction or valve box covers or surveyors stakes so they become extremely dangerous creating enormous liability.

Personnel responsible for roadways have observed that leveling five manhole lids by the inventive method in approximately two hours and at a total cost, including materials and labor, of $500. Using a prior method, the same project would have taken roughly a day and a half and, after the costs associated with permits, barriers and labor, would have cost between $3,000 and $4,000. These repairs have now been in place for approximately one year and show no signs of wear and tear.

Personnel provided another comparison. The manhole lid-surround leveling process was completed using the disclosed method and took approximately 20 minutes at a total material cost of $75. In contrast, personnel said the typical cost for such a repair would be about $500. Also leveling a junction box and valve cover boxes cost approximately $50 using the inventive process but would cost several hundred dollars to do conventionally.

An important aspect of the inventive process is not just the filling material, but also the primer. In this case, using the “primer” increases the integrity and adhesion of the repair and helps control the curing time. Also, this process may be done whether the pothole is wet or dry. Since the density of the filling material may be controlled, the filling material does not need to be removed because it is dense enough to support even a new surface asphalt without any additional treatment when a repaired roadway is to be resurfaced.

One of the most significant benefits is that the entire process may be done using individual kits that have a long shelf life so they are affordable as well as convenient for single, reactive repair requirements.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof

The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.

While the preferred embodiment to the invention had been The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described. 

What is claimed:
 1. A method for filling a pot hole in a road utilizing a filling material, a primer and a catalyst, the method comprising the steps of: applying the primer to an edge of the pot hole; pouring the filling material into the pot hole; and curing the filling material to form a patch that is even with the road.
 2. The method of claim 1 in which the primer is applied to the entire surface of the pot hole.
 3. The method of claim 1 in which the step of applying the primer is preceded by a step of cleaning the pot hole.
 4. The method of claim 1 in which the step of curing the filling material comprises spraying the surface of the filling material with the catalyst.
 5. The method of claim 1 in which the pot hole is a defect near a manhole, and the pot hole is filled with a filling material and the primer.
 6. A method of applying a filling material in the space around a manhole structure to prevent deterioration of a collar formed from concrete, the method comprising the steps of: pouring the concrete into the space around the manhole structure to form the collar; applying the filling material over the collar; and curing the filling material to form a rigid support around the manhole structure which absorbs impacts produced when vehicles pass over the manhole structure.
 7. The method of claim 6 in which the primer is applied to the entire surface of the wet concrete.
 8. The method of claim 6 in which the step of applying the primer is preceded by a step of leveling the concrete.
 9. The method of claim 6 in which the step of curing the filling material comprises spraying the surface of the filling material with the primer.
 10. The method of claim 6 in which the step of curing the filling material comprises spraying the surface of the filling material with catalyst and then water.
 11. A method for raising the level of a manhole structure and collar to the level of a resurfaced road utilizing a cover, a separator ring, and a filling material, the method comprising the steps of: applying the cover on top of the manhole structure and the collar; erecting protection of the manhole cover and ring from being covered with the asphalt; pouring the asphalt over the road; removing the protection from the manhole cover and ring; positioning the separator ring around the lid; applying the filling material over the manhole structure and the collar to form a secondary lid and surround each having a height equal to the resurfaced road; and removing the separator ring from around the lid.
 12. The method of claim 11 wherein a primer is applied to manhole cover and ring before applying the filling material.
 13. The method of claim 12 in which the step of applying the filling material is followed by a step of leveling the filling material.
 14. The method of claim 11 in which the step of removing the separator ring is followed or preceded by curing the filling material.
 15. The method of claim 14 in which comprises the step of curing the filling material comprises spraying the surface of the filling material with the catalyst.
 16. The method of claim 14 in which the step of curing the filling material comprises spraying the surface of the filling material with primer and then water.
 17. A separator ring for separating a manhole cover and its underlying structure, the separator ring comprising An elongated body capable of bending in a circle or other shape and having two opposing ends; and Male and female adjusters, each located at an opposing end, the male adjuster fitting inside the female end to establish the length around the manhole cover.
 18. The separator ring of claim 17 further comprising a handle or separator ring lifter to pull the separator ring free from the filling material placed atop the manhole cover. 